MC/BB swap on Saturday

[karstic]

Cal and I will be swapping a WJ brake booster and master cylinder in my '92 on Saturday at my house in Fullerton. If anyone is interested in seeing it done first hand feel free to stop by. Afterward you can help build the planters in the backyard. We'll be starting around 10am and the swap should take an hour or two.

2024 W. Olive Avenue, Fullerton

[silverslk]

I might swing by. I gotta get a new master for my 93 real soon. Its starting to leak fluid out the booster.........not good. Brakes suck so I am not driving it much.

[Clean Racing]

Funny... I just modded mine and one other WJ booster that I am installing tomorrow... Have fun and dont grind too much off the end of the rod...:D

[cal]

His isn't a renix, so we won't need to remove material from the end of the rod, IIRC.

[GrimmJeeper]

His isn't a renix, so we won't need to remove material from the end of the rod, IIRC. yea dont remove any material from his rod, its short enough as it is :D

[karstic]

yea dont remove any material from his rod, its short enough as it is :D

STFU

btw Got my ballz?

[GrimmJeeper]

STFU

btw Got my ballz? yep, and if you ever want to see em again bring the ransom money to the meet n greet tonight :D

[erikwylie]

Here we go with the Rod and Ballz talk again!

[karstic]

Here we go with the Rod and Ballz talk again!

C'mon don't you know that every conversation eventually degrades into poop talk or rod and ballz talk. Get with the program.

[XJMilan]

I have a question about this install, do you plan on putting the 1/4 inch spacers (I used washers) on the bolts between the booster and firewall? I did this mod last weekend and my pedal feels weird when I hit the brakes. The rod wasn't exactly lined up with the hole in the brake pedal. It was alittle higher so just pulled the rod down alittle to line it up. It is almost like I needed a smaller spacer on the top two bolts to angle it down alittle. :dunno:

[erikwylie]

C'mon don't you know that every conversation eventually degrades into poop talk or rod and ballz talk. Get with the program.

I am with the program those are 3 of my top ten subjects!!!!:gee: Hasta

[GrimmJeeper]

I have a question about this install, do you plan on putting the 1/4 inch spacers (I used washers) on the bolts between the booster and firewall? I did this mod last weekend and my pedal feels weird when I hit the brakes. The rod wasn't exactly lined up with the hole in the brake pedal. It was alittle higher so just pulled the rod down alittle to line it up. It is almost like I needed a smaller spacer on the top two bolts to angle it down alittle. :dunno:

its rob right? hows that thing comin along? got your front end back together yet?

-mike

[cal]

I have a question about this install, do you plan on putting the 1/4 inch spacers (I used washers) on the bolts between the booster and firewall? I did this mod last weekend and my pedal feels weird when I hit the brakes. The rod wasn't exactly lined up with the hole in the brake pedal. It was alittle higher so just pulled the rod down alittle to line it up. It is almost like I needed a smaller spacer on the top two bolts to angle it down alittle. :dunno:


No. I have done the mod without the spacer several times and not had a problem at all.. Good pedal, good braking. You have to do a little more bending of the pinch seam to get the booster to seat right, but its not difficult.

[Clean Racing]

No. I have done the mod without the spacer several times and not had a problem at all.. Good pedal, good braking. You have to do a little more bending of the pinch seam to get the booster to seat right, but its not difficult.

Make sure you guys take good pictures... I would but I am by myself today...

[XJMilan]

its rob right? hows that thing comin along? got your front end back together yet?

-mike
It is coming along, slowly. The front end is fixed, or at least fixed enough for me. I have about 90% of my lift completed. Keeping it simple but it netted my 5" at all four corners on 31's. I keep running into little problems but I hope to have it back on the road this weekend.

Rob

[XJMilan]

No. I have done the mod without the spacer several times and not had a problem at all.. Good pedal, good braking. You have to do a little more bending of the pinch seam to get the booster to seat right, but its not difficult.
I am debating taking them out but I don't want to have to bleed the brakes again. Those things were a bitch to get all the air out for some reason and I think I still have alittle bit in there. I need to drive it for more than a few hundred yards that I have driven it since the install before I make my decision though. I am pretty sure I already have the pinch seam bent enough thanks to my 2.5# sledge.

Rob

[Skwerly]

Odd, I've never had a prob bleeding brakes, takes only like 5 min for both sides, i wonder what the deal is?

[XJMilan]

I suspect it is some sort of leak at one of the connections. All of the flair nuts were rounded so I had to cut the lines and re-flair them. I sprayed them all with brake cleaner and wiped them down good after install but one has the smallest bit of fluid on it after sitting over night and so far no amount of tightening it keeps it from getting wet with fluid. It is not enough to build into a drip but just enough to make the connection wet. That is what I am currently concentrating on fixing and hopefully that will be it.

Rob

[Clean Racing]

I suspect it is some sort of leak at one of the connections. All of the flair nuts were rounded so I had to cut the lines and re-flair them. I sprayed them all with brake cleaner and wiped them down good after install but one has the smallest bit of fluid on it after sitting over night and so far no amount of tightening it keeps it from getting wet with fluid. It is not enough to build into a drip but just enough to make the connection wet. That is what I am currently concentrating on fixing and hopefully that will be it.

Rob


Sounds like you need to redo the lines, maybe the flares are cracked... I just did the swap today for a buddy, and making the lines was the hardest part.... but it is real nice to lock up the brakes....

[Clean Racing]

Well Karstic and Cal??? Any updates, thoughts, mods, pics??? How did it go or not go?? I am curious...:twak:

[cal]

The mod went very easy, it was my first time doing it with a 91+. I started to take pictures, but then got involved and forgot, I have nothing worth sharing. End result was better brakes, but with the Vanco big brake kit already on the rig, there wasn't as much improvement as might have been possible - although its suspected thats due to the drum brakes in the rear not being in tip top shape. With a pump of the brakes first, stopping power went WAY up. karstic's going to adjust the rear's in and see what happens from there.

I'd like to find a larger bore/volume master that bolts to the WJ booster.

[karstic]

Ok I don't know what happened between yesterday and today, but


GOTDAMN! I got BRAKES!

I don't know where the play from yesterday went but it wasn't there today.

The swap was very straight forward. The distance from the mounting surface on the back of the booster to the end of the rod was within a 1/8" between the the two boosters. I didn't have to use the 1/4" spacer between the booster and firewall. The major difference between the two boosters was in the rod that attaches to the brake pedal. On the WJ booster the mounting hole is on the centerline of the rod. On the XJ booster the mounting hole is offset below the the centerline of the rod. There was enough play in the WJ rod to be pull it down and slip it on the mounting stud on the brake pedal. I didn't have to grind the WJ rod at all.

After driving it today. I'm pretty damn impressed. I'll probably drive the XJ to work tomorrow to get some more feedback on the set up.

[corbinafly]

GOTDAMN! THAT'S AWESOME:party: !

[karstic]

BTW a big Thank You to Cal and Kyung for the help.

[corbinafly]

GOTDAMN! NO PROBLEM!

[cal]

hahahaha

just keep me posted on how it is working.

[karstic]

So this morning drove 91 to 57 to 5 to Irvine. Then 5 to 55 to Edinger to the office in HB (Bolsa Chica and Warner)

I have an intermittent problem where it seems like the brakes are dragiing and there is absoluty no play in the pedal. It's happened both on the freeway and on surface streets. Couple of taps on the pedal and the problem goes away.

What say you?

[cal]

I'm wondering if we need to modify the pedal to raise the rod up a hair

[GrimmJeeper]

it sounds like its binding up a bit.

[karstic]

I'm wondering if we need to modify the pedal to raise the rod up a hair

Or like what Rob was saying to place some washers on the bottom studs.

I'll see what it's like on the drive home.

[cal]

Or like what Rob was saying to place some washers on the bottom studs.


I didnt think of that, it could work yes.

[XJMilan]

I drove mine a bit yesterday and I wish I didn't space it 1/4 inch. With the booster not snug against the firewall I get alot of engine noise coming into the cab. :puke: I haven't run into the same problems you are having Karstic but I am having problems of my pedal keeping pressure. Please keep us posted of any more changes you do to get it working right. I think I am going to remove those washers and see if I can come up with a better way to get the rod and pedal aligned better. Plus, I have to grind some more off the rod.:doh:

Rob

[karstic]

How easy is it to get the pedal off?

Is it just the 4 nuts that hold the booster?